U.S. patent application number 13/104642 was filed with the patent office on 2011-11-17 for fuel filter.
Invention is credited to Daniel E. Bause, Gerard W. Bilski, Weston H. Gerwin, Ronald P. Rohrbach, Scott J. Tabb, Peter D. Unger, Gary B. Zulauf.
Application Number | 20110277374 13/104642 |
Document ID | / |
Family ID | 39269133 |
Filed Date | 2011-11-17 |
United States Patent
Application |
20110277374 |
Kind Code |
A1 |
Tabb; Scott J. ; et
al. |
November 17, 2011 |
FUEL FILTER
Abstract
Disclosed herein is an apparatus and method for adding a
lubricating additive to a diesel fuel. In one embodiment, a system
for controlling the release of a fuel additive into a diesel fuel
is provided, the system having: a housing having at least one inlet
opening and at least one outlet opening configured to define a flow
path therethrough; filter media disposed in the flow path, the
filter media comprising an adsorbent that removes sulfur containing
compounds from diesel fuel passing through the housing; an additive
cartridge configured to disperse a lubricating additive into the
diesel fuel; a controller for controlling the amount of lubricating
additive that is released from the additive cartridge into the
diesel fuel; and at least one sensor configured to monitor the
lubricant additive content in the diesel fuel and provide a signal
indicative of the lubricant additive content in the diesel fuel to
the controller, wherein the controller releases the additive from
the additive cartridge based upon the signal received from the at
least one sensor.
Inventors: |
Tabb; Scott J.; (Canton,
MI) ; Rohrbach; Ronald P.; (Flemington, NJ) ;
Zulauf; Gary B.; (Findlay, OH) ; Unger; Peter D.;
(Convent Station, NJ) ; Gerwin; Weston H.;
(Perrysburg, OH) ; Bause; Daniel E.; (Flanders,
NJ) ; Bilski; Gerard W.; (Perrysburg, OH) |
Family ID: |
39269133 |
Appl. No.: |
13/104642 |
Filed: |
May 10, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11864962 |
Sep 29, 2007 |
7938960 |
|
|
13104642 |
|
|
|
|
60827569 |
Sep 29, 2006 |
|
|
|
Current U.S.
Class: |
44/300 ;
210/96.1 |
Current CPC
Class: |
F02M 37/34 20190101;
F02M 25/00 20130101; B01J 20/08 20130101; C10L 1/188 20130101; C10L
1/19 20130101; C10L 1/224 20130101; C10L 10/08 20130101; B01D 15/00
20130101; B01J 20/06 20130101 |
Class at
Publication: |
44/300 ;
210/96.1 |
International
Class: |
C10L 1/10 20060101
C10L001/10; F02M 37/22 20060101 F02M037/22; B01D 15/08 20060101
B01D015/08; B01D 35/02 20060101 B01D035/02 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Embodiments of this invention may have been made with
governmental support under Contract No. DE-FC26-02NT41219.
Therefore, the U.S. Government may have a paid-up license to
portions or embodiments of this invention and the right in limited
circumstances to require the patent owner to license to others on
reasonable terms as provided for by the terms, of Contract No.
DE-FC26-02NT41219.
Claims
1. A method for adding a lubricating additive to a diesel fuel,
comprising: passing the diesel fuel through a fuel filter
comprising an adsorbent that removes sulfur containing compounds
from the diesel fuel; and releasing a lubricant additive into the
diesel fuel after it has passed through the adsorbent, wherein the
lubricant additive is released into the diesel fuel by a pump
controlled by a controller and wherein the controller is coupled to
at least one sensor configured to monitor the lubricant additive
content in the diesel fuel.
2. The method as in claim 1, wherein the adsorbent comprises an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3.
3. The method as in claim 2, wherein the fuel filter has at least
one inlet opening and at least one outlet opening, the at least one
inlet opening, the fuel filter and the at least one outlet opening
define a flow path through the fuel filter and the adsorbent is
disposed in the flow path and the lubricant additive is stored in
an additive cartridge located within the filter, the additive
cartridge being configured to disperse the lubricant additive into
diesel fuel passing through the filter.
4. The method as in claim 1, wherein the fuel filter has at least
one inlet opening and at least one outlet opening, the at least one
inlet opening, the fuel filter and the at least one outlet opening
define a flow path through the fuel filter and the adsorbent is
disposed in the flow path and the lubricant additive is stored in
an additive cartridge located within the filter, the additive
cartridge being configured to disperse the lubricant additive into
diesel fuel passing through the filter.
5. The method as in claim 4, wherein the additive cartridge is
disposed between an inlet opening of the filter and the
adsorbent.
6. The method as in claim 4, wherein the additive cartridge is
disposed between an outlet opening of the filter and the
adsorbent.
7. The method as in claim 6, wherein the adsorbent comprises an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3.
8. The method as in claim 1, wherein the adsorbent comprises an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3 and the fuel filter has at least one inlet
opening and at least one outlet opening, the at least one inlet
opening, the fuel filter and the at least one outlet opening define
a flow path through the fuel filter and the adsorbent is disposed
in the flow path and the lubricant additive is stored in a pair of
additive cartridges located within the filter, the pair of additive
cartridges being configured to disperse the lubricant additive into
diesel fuel passing through the filter, one of the pair of additive
cartridges being disposed between an inlet opening of the filter
and the adsorbent and the other one of the additive cartridges
being disposed between an outlet opening of the filter and the
adsorbent.
9. The method as in claim 1, wherein the adsorbent comprises an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3 and the fuel filter has at least one inlet
opening and at least one outlet opening, the at least one inlet
opening, the fuel filter and the at least one outlet opening define
a flow path through the fuel filter and the adsorbent is disposed
in the flow path and the lubricant additive is stored in an
additive cartridge located within the filter, the additive
cartridge being configured to disperse the lubricant additive into
diesel fuel passing through the filter.
10. The method as in claim 1, wherein the fuel filter has at least
one inlet opening and at least one outlet opening, the at least one
inlet opening, the fuel filter and the at least one outlet opening
define a flow path through the fuel filter and the adsorbent is
disposed in the flow path and the lubricant additive is stored in
an additive cartridge located within the filter, the additive
cartridge being configured to disperse the lubricant additive into
diesel fuel passing through the filter, wherein the adsorbent
comprises an inorganic oxide having a surface acidity characterized
by a pK.sub.a of at least -3 and the surface acidity of the
inorganic oxide is attributable to Lewis acids.
11. The method as in claim 10, wherein the inorganic oxide is
characterized by a surface that is substantially free of applied
compounds comprising Group VIIIA metals, Group IV metals, alkali
metals, alkaline earth metals, and mixtures thereof.
12. The method as in claim 10, wherein the inorganic oxide is
substantially free of compounds comprising Group VIIIA metals,
alkali metals, alkaline earth metals, and mixtures thereof.
13. The method as in claim 6, wherein the inorganic oxide is at
least one of alumina, kaolinite (either sodium, ammonium or
hydrogen forms), montmorillonite (either sodium, ammonium or
hydrogen forms), silca magnesia, alumina-boria, activated alumina,
zeolites, aluminosilicates, silica gels, clay, active clay, silicon
dioxide, mesoporous silica porous material (FSM), silica alumina
compounds, silica, alumina phosphate compounds, super acids, super
acids-sulfated, titania, sulfated zironia, titanium dioxide,
hafnium oxide, and mixtures thereof.
14. The method as in claim 1, wherein the inorganic oxide has a
surface acidity characterized by a pK.sub.a of least -6.
15. The method as in claim 1, wherein the inorganic oxide has a
surface acidity characterized by a pK.sub.a of least -8.
16. An system for controlling the release of a fuel additive into a
diesel fuel, the system comprising: a housing having at least one
inlet opening and at least one outlet opening configured to define
a flow path therethrough; filter media disposed in the flow path,
the filter media comprising an adsorbent that removes sulfur
containing compounds from diesel fuel passing through the housing;
an additive cartridge configured to disperse a lubricating additive
into the diesel fuel; a controller for controlling the amount of
lubricating additive that is released from the additive cartridge
into the diesel fuel; and at least one sensor configured to monitor
the lubricant additive content in the diesel fuel and provide a
signal indicative of the lubricant additive content in the diesel
fuel to the controller, wherein the controller releases the
additive from the additive cartridge based upon the signal received
from the at least one sensor.
17. The system as in claim 16, wherein the adsorbent comprises an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3.
18. The system as in claim 17, wherein the adsorbent material is
positioned in the flow path between the at least one inlet opening
and the additive cartridge and the fuel must pass through the
adsorbent before contacting the additive cartridge.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/864,962 filed Sep. 29, 2007, which claims
the benefit of U.S. Provisional Patent Application Ser. No.
60/827,569 filed Sep. 29, 2006, the contents each of which are
incorporated herein by reference thereto.
BACKGROUND
[0003] Exemplary embodiments of the present invention relate to a
fuel filter and method for the removal of sulfur containing
compounds from a post-refinery fuel stream more particularly
exemplary embodiments relate to a fuel filter and method for the
removal of sulfur containing compounds wherein the filter provides
an additive to the fuel.
[0004] There continues to be environmental concern relating to air
pollution stemming from use of internal combustion engines,
especially those used in transportation applications such as cars,
trucks, boats and the like, and stationary power sources such as
diesel generators and the like. In addition to being a direct
source of pollution in the form of SOx, sulfur also poisons the
catalytic surface of exhaust after treatment devices. By reducing
sulfur in the fuel and therefore the exhaust, the useful life of
exhaust after treatment devices is extended. In addition, and since
many internal combustion engines employ an exhaust gas
recirculation system there is also a desire to remove the sulfur
from the exhaust gas.
[0005] New power sources such as fuel cells will also require fuel
streams to have similar or lower levels of sulfur. Fuel cells burn
hydrogen that has been reformed from various hydrocarbon fuels,
such as gasoline. Sulfur will poison the active surfaces of the
fuel cell, thus shortening its life.
[0006] As a result, various governments and regulatory bodies
continue to enact legislation intended to substantially lower the
acceptable levels of sulfur and sulfur containing compounds present
in the fuels used in internal combustion engines.
[0007] The U.S. EPA, for instance, has enacted regulations
requiring diesel fuel producers to phase in the production of low
sulfur diesel fuel (equal to or less than 15 ppm sulfur) beginning
in 2006 and ending in 2010. Similarly, from 2004 to 2006, gasoline
sulfur levels were reduced from 50 ppm to 30 ppm. The need for
commercially available fuels having continually lower levels of
sulfur containing compounds creates new problems for manufacturers
of such fuels, i.e., the refining industry.
[0008] The introduction of low-sulfur diesel fuels has also caused
problems with fuel-injection equipment because the fuel's
lubricating properties were reduced by the hydrotreating process
needed to lower the sulfur content. The majority of the
fuel-lubricated distributor injection pumps for passenger cars and
small trucks showed increase wear if the low-sulfur diesel fuel is
not treated with lubricant additives. Increased wear reduced the
injection pump's service life and caused engine power loss, higher
emissions, and fuel consumption, poor driveability, and
difficulties when starting.
[0009] Adding lubrication additives to the diesel fuels appears to
be the only viable solution for overcoming the aforementioned
problems.
[0010] Additionally, there are issues with the incompatibilities
with additized diesel fuel in pipelines when a jet-fuel is also
transported in the same pipelines. Consequently additization will
have to be done after the fuel is distributed and after the
refinery.
[0011] Furthermore and since the refined diesel fuel still has some
sulfur in it there is a desire to provide a fuel filter in the
system of an internal combustion engine or other device wherein the
fuel filter is configured to further reduce the sulfur content of
the fuel. For example, one approach for removing the sulfur from
the fuel is to place an adsorbant in a filter positioned to filter
the fuel stream however, these adsorbants may also filter out
desired properties or additives of the fuel namely, lubrication
additives which were added to the fuel to address the
aforementioned issues associated with low sulfur diesel fuels.
[0012] Accordingly, it is desirable to provide a fuel filter that
delivers lubricating additives to the fuel.
SUMMARY OF THE INVENTION
[0013] Disclosed herein are fuel filters and processes for removing
sulfur-containing compounds from a post refinery fuel stream.
[0014] In one exemplary embodiment, a fuel filter is provided
wherein the fuel filter provides lubricant additives to the fuel
being filtered.
[0015] In another exemplary embodiment, a fuel filter is provided
wherein the fuel filter removes sulfur containing compounds from
the fuel and the fuel filter provides lubricant additives to the
fuel after is has been filtered.
[0016] In accordance with one exemplary embodiment a method for
adding a lubricating additive to a diesel fuel is disclosed, the
method comprising: passing the diesel fuel through a fuel filter
comprising an adsorbent configured to remove sulfur from the diesel
fuel; and releasing a lubricant or lubricity additive into the
diesel fuel after it has passed through the adsorbent.
[0017] In accordance with another exemplary embodiment, a system
for controlling the release of a fuel additive into a diesel fuel
is provided, the system having: a housing having at least one inlet
opening and at least one outlet opening configured to define a flow
path therethrough; filter media disposed in the flow path, the
filter media comprising an adsorbent that removes sulfur containing
compounds from diesel fuel passing through the housing; an additive
cartridge configured to disperse a lubricating additive into the
diesel fuel; a controller for controlling the amount of lubricating
additive that is released from the additive cartridge into the
diesel fuel; and at least one sensor configured to monitor the
lubricant additive content in the diesel fuel and provide a signal
indicative of the lubricant additive content in the diesel fuel to
the controller, wherein the controller releases the additive from
the additive cartridge based upon the signal received from the at
least one sensor.
DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1-3 are schematic illustrations of fuel filters in
accordance with exemplary embodiments of the present invention;
[0019] FIG. 4 is a schematic illustration of an alternative
exemplary embodiment of the present invention;
[0020] FIGS. 5-8C illustrate fuel filters and lubricity additive
cartridges constructed in accordance with alternative exemplary
embodiments of the present invention; and
[0021] FIG. 9 is a schematic illustration of still another
alternative exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0022] This application is related to the following U.S. patent
application Ser. Nos., 11/081,796, filed Mar. 15, 2005, and
11/674,913, filed Feb. 14, 2007, the contents each of which are
incorporated herein by reference thereto.
[0023] Disclosed herein is a fuel filter that is capable of
providing lubricant additives to a fuel being filtered by the
filter. In another exemplary embodiment, the fuel filter is also
configured to remove sulfur containing compounds from a post
refinery fuel stream.
[0024] The term "post refinery fuel stream" or "post refinery fuel"
as used herein refers to a fuel or fuel stream (used
interchangeably herein) that is manufactured by a petroleum
refinery. In one exemplary embodiment, post refinery fuel refers to
a fuel manufactured by a petroleum refinery employing at least one
sulfur removing technology. In one embodiment, a post refinery fuel
stream will comprise sulfur containing compound in a concentration
of no more than 2000 ppm. In another embodiment, a post refinery
fuel stream will comprise sulfur-containing compounds in a
concentration of no more than 100 ppm. In one exemplary embodiment,
a post refinery fuel stream will comprise sulfur-containing
compound in a concentration of no more than 15 ppm. In one
embodiment, a post refinery fuel stream contains a population of
sulfur species present as various substituted alkyl, benzo, and
dibenzothiophenes.
[0025] As used herein `fuel filter` is intended in one embodiment
to describe a fuel filter designed to remove sulfur-containing
compounds found in fuels. It is also understood that in accordance
with exemplary embodiments a separate fuel filter may be provided
to remove contaminants from the fuel (e.g., a typical of non-sulfur
removing fuel filter). Alternatively, a single fuel filter
configured for both removal of sulfur-containing compounds and
filtering of other contaminants is contemplated to be within the
scope of alternative embodiments of the disclosed fuel filters and
methods of using the same. In any of the aforementioned
arrangements exemplary embodiments of the present invention are
directed to a fuel filter, which is also configured to provide a
lubricating additive to the fuel. As used herein "lubricating
additive" refers to an additive added to the refined fuel in order
to overcome the deleterious effects of the de-sulfurization
process, non-limiting examples of "lubricating additives" include
but are not limited to amides, esters and acids. It will be
understood that lubricants suited for use as fuel lubricating
additives for internal combustion engines, are lubricants
comprising amides, esters, acids, or a combination comprising two
or more of the foregoing. It is advantageous that the lubricants
have a viscosity or flash point suitable for use in an internal
combustion engine.
[0026] Non-limiting examples of lubricating additives for diesel
fuel are found in the following U.S. Pat. Nos. 6,562,086;
6,361,573; 6,187,939; 6,080,212; 5,997,593; and 5,853,436 the
contents each of which are incorporated herein by reference
thereto.
[0027] The disclosed fuel filters and methods can be used with
power sources such as internal combustion engines and fuel cells
employed in both stationary systems and motor vehicles.
Illustrative examples of internal combustion engines include
gasoline powered engines and diesel engines.
[0028] The disclosed fuel filters and methods are generally
suitable for use with fuel cells having an anode, a cathode, and an
electrolyte in between the two electrodes wherein typically an
oxidation reaction (e.g., H.sub.2.fwdarw.2H.sup.++2e) takes place
at the anode and a reduction reaction (e.g.,
O.sub.2+2H.sub.2O+4e.fwdarw.4OH.sup.-) takes place at the
cathode.
[0029] Illustrative examples of fuel cells include Proton Exchange
Membrane or Polymer Electrolyte Membrane (PEM) fuel cells,
phosphoric acid (PA) fuel cells, molten carbonate (MC) fuel cells,
solid oxide (SO) fuel cells, and alkaline fuel cells.
[0030] Illustrative examples of stationary systems include
generators and power plants.
[0031] Illustrative examples of motor vehicles include cars,
trucks, boats, personal water craft, semi-trucks, construction
devices such as bulldozers and cranes, small engine devices such as
lawn mowers and tractors, and the like.
[0032] In one embodiment, the fuel filter for removing or reducing
the concentration of sulfur containing compounds will be installed
on such motor vehicles such that any fuels introduced into the
vehicle must pass through the fuel filter before entering the
internal combustion engine. In such applications, the fuel filter
for removing sulfur-containing compounds, i.e., a sulfur reducing
or removing fuel filter may be referred to as an on-board vehicle
sulfur polishing or desulfurization component or process.
[0033] In one exemplary embodiment, the sulfur removing filter will
be used as an on-board vehicle desulfurization component that may
also be a part of an emission control system wherein the filter
releases captured sulfur containing compounds into the fuel stream
during a regeneration process of a NOx adsorber, wherein the
regeneration of the NOx adsorber is conducted in accordance with
technologies known to those skilled in the related arts.
[0034] In addition, the disclosed fuel filters and methods can be
used in traditional fuel distribution systems that distribute post
refinery fuel streams.
[0035] Such fuel distribution systems may be characterized by (i) a
refinery that manufactures the post refinery fuel stream, (ii) one
or more interim storage devices, and (iii) one or more fuel
consuming articles or vehicles having a power source that requires
refueling. Illustrative examples of interim storage devices include
underground and above ground storage tanks, tanker trucks, fuel
discharge or dispensing devices, connecting piping, and the like.
Fuel consuming articles or vehicles having a power source that
consumes fuel include the descriptions above for motor vehicles and
stationary systems.
[0036] Illustrative post-refinery fuel streams include gasoline,
kerosene, heating oil, jet fuel, cracked-gasoline or diesel fuel.
In one exemplary embodiment, the fuel will be diesel fuel.
[0037] The term "gasoline" denotes a mixture of hydrocarbons
boiling in the range of from about 100 degrees Fahrenheit to about
400 degrees Fahrenheit, or any fraction thereof. Examples of
suitable gasoline include, but are not limited to, hydrocarbon
streams in refineries such as naphtha, straight-run naphtha, coker
naphtha, catalytic gasoline, naphtha, alkylate, isomerate,
reformate, and the like and combinations thereof.
[0038] The term "cracked-gasoline" denotes a mixture of
hydrocarbons boiling in the range of from about 100 degrees
Fahrenheit to about 400 degrees Fahrenheit, or any fraction
thereof, that are products from either thermal or catalytic
processes that crack larger hydrocarbon molecules into smaller
molecules. Examples of suitable thermal processes include, but are
not limited to, coking, thermal cracking, visbreaking, and the like
and combinations thereof. Examples of suitable catalytic cracking
processes include, but are not limited to, fluid catalytic
cracking, heavy oil cracking, and the like and combinations
thereof. Thus, examples of suitable cracked-gasoline include, but
are not limited to, coker gasoline, thermally cracked gasoline,
fluid catalytically cracked gasoline, heavy oil cracked gasoline,
and the like and combinations thereof.
[0039] The term "diesel fuel" denotes a mixture of hydrocarbons
boiling in the range of from about 300 degrees Fahrenheit to about
750 degrees Fahrenheit, or any fraction thereof. Examples of
suitable diesel fuels include, but are not limited to, light cycle
oil, kerosene, jet fuel, straight-run diesel, hydrotreated diesel,
and the like and combinations thereof.
[0040] The sulfur containing compounds removed by the disclosed
fuel filter may in general be any sulfur containing compound
normally found in fuels intended for use in internal combustion
engines. The disclosed fuel filters may remove one or more of such
compounds from a fuel stream.
[0041] The term "sulfur" or "sulfur containing compound" denotes
sulfur in any form such as elemental sulfur or a sulfur compound
normally present in a hydrocarbon-containing fluid such as cracked
gasoline or diesel fuel. Examples of sulfur which can be present
during a disclosed process, include, but are not limited to,
hydrogen sulfide, carbonyl sulfide (COS), carbon disulfide
(CS.sub.2), mercaptans (RSH), organic sulfides (R--S--R), organic
disulfides (R--S--S--R), thiophene, substituted thiophenes, organic
trisulfides, organic tetrasulfides, benzothiophene, alkyl
thiophenes, alkylated benzothiophenes, dibenzothiophenes, alkylated
dibenzothiophenes, and the like and combinations thereof as well as
the heavier molecular weights of same which are normally present in
a diesel fuel of the types contemplated for use in a process of the
present invention, wherein each R can be an alkyl or cycloalkyl or
aryl group containing one carbon atom to ten carbon atoms.
[0042] In one exemplary embodiment, the sulfur-containing compounds
removed by the disclosed filter or process will be sulfur
containing aromatic compounds. In one embodiment, the sulfur
containing compounds removed by the disclosed fuel filter include
benzothiophene, dibenzothiophene, and derivatives thereof.
[0043] In one embodiment, the disclosed fuel filters and methods
are suitable for use with the interim storage devices of a
traditional fuel distribution system. It will be appreciated that
such methods and fuel filters may be employed at numerous locations
within such interim storage devices. For example, a fuel
desulfurization filter could be incorporated into the dispensing
device at the point of use or at the entrance or exit of an interim
storage device. In another embodiment, a fuel desulfurization
filter could be incorporated at one or more central distribution
points.
[0044] The disclosed fuel filters are also suitable for use with
commercially available post refinery fuels directly inserted into
motor vehicles by a vehicle operator through a fuel intake opening
in the vehicle. In one exemplary embodiment, the post refinery
fuels will be unadulterated, that is, they will not be subject to
any pretreatment steps prior to passing through the disclosed fuel
filters except for those employed by the original manufacturing
refinery. Such fuels may be referred to as unadulterated post
refinery fuels.
[0045] Fuels or fuel streams that pass through the disclosed fuel
filters and methods may be referred to as `clean fuels` or
`polished fuels`.
[0046] In one embodiment, the unfiltered or `contaminated` post
refinery fuel streams may comprise sulfur concentrations of from
about 6 ppm to 500 ppm. In another embodiment, the disclosed
filters and method may be used with post refinery fuel streams
having sulfur concentrations of from about 15 ppm or less. In one
exemplary embodiment, the disclosed filters and method may be used
with post refinery fuel streams having sulfur concentrations of
from about 9 ppm or less. In one embodiment, the disclosed filters
and method may be used with refinery fuel streams having sulfur
concentrations of from about 6 ppm to about 15 ppm.
[0047] In one embodiment, the disclosed method will result in
filtered or clean fuel streams having a reduced concentration of
sulfur; especially sulfur concentrations of 3 ppm or less.
[0048] In accordance with an exemplary embodiment of the present
invention the disclosed fuel filters may comprise an adsorbent
comprising an inorganic oxide having a surface acidity
characterized by a pK.sub.a of at least -3. In one embodiment, the
disclosed fuel filters will comprise an adsorbent consisting
essentially of an inorganic oxide having a surface acidity
characterized by a pK.sub.a of at least -3.
[0049] The term "inorganic oxide" as used herein refers to porous
materials having pores large enough to adsorb sulfur-containing
aromatic compounds.
[0050] In one embodiment, the inorganic oxides may be characterized
by a surface area of at least 50 m.sup.2/g while in another
embodiment, the inorganic oxides may be characterized by a surface
area of from about 150 m.sup.2/g to about 500 m.sub.2/g.
[0051] In one embodiment, suitable inorganic oxides will have pores
in excess of 50 angstroms.
[0052] Illustrative examples of suitable inorganic oxides include
alumina, kaolinite (either sodium, ammonium or hydrogen forms),
montmorillonite (either sodium, ammonium or hydrogen forms), silca
magnesia, alumina-boria, activated alumina, zeolites,
aluminosilicates, silica gels, clay, active clay, silica gel,
silicon dioxide, mesoporous silica porous material (FSM), silica
alumina compounds, silica, alumina phosphate compounds, super
acids, super acids-sulfated, titania, sulfated zironia, titanium
dioxide, hafnium oxide, and mixtures thereof and the like. In one
exemplary embodiment, suitable inorganic oxides will be at least
one of alumina, zeolite, silica alumina compounds, silica, alumina
phosphate compounds, super acids, silica gels, titanates, zironia,
titanium dioxide, hafnium oxide, and mixtures thereof.
[0053] In one especially exemplary embodiment, the inorganic oxide
will be alumina. The term "alumina" as used herein refers to
Al.sub.2O.sub.3.
[0054] Although many types and phases of alumina are suitable for
use in the disclosed fuel filters and methods, in one embodiment,
the inorganic oxide will be at least one of gamma alumina, eta
alumina, and mixtures thereof.
[0055] However, not withstanding the foregoing, only those
inorganic oxides having a surface acidity characterized by a
pK.sub.a of at least -3 are suitable for use in the disclosed fuel
filters and methods.
[0056] It will be appreciated that the term "surface acidity" as
used herein refers to a surface that has an acidity measurable by
visual color change via an acid base indicator such as
dicinnamalacetone.
[0057] In one embodiment, the disclosed fuel filters will comprise
an adsorbent comprising, consisting essentially of, or consisting
of an inorganic oxide having a surface acidity characterized by a
pK.sub.a of least -3. In one embodiment, the disclosed fuel filters
will comprise an adsorbent comprising, consisting essentially of,
or consisting of an inorganic oxide having a surface acidity
characterized by a pK.sub.a of least -6. In another embodiment, the
disclosed fuel filters will comprise an adsorbent comprising,
consisting essentially of, or consisting of an inorganic oxide
having a surface acidity characterized by a pK.sub.a of least -8.
In another embodiment, the disclosed fuel filters will comprise an
adsorbent comprising, consisting essentially of, or consisting of
an inorganic oxide having a surface acidity characterized by a pKa
of from about -3 to about -8. It will be appreciated the function
of the adsorbent is the adsorption and removal of sulfur-containing
compounds from a fuel stream.
[0058] Suitable inorganic oxides may be obtained by the calcination
of an otherwise suitable inorganic oxide. In one embodiment,
otherwise suitable inorganic oxides will those be inorganic oxides
which lack the requisite surface acidity but which are otherwise as
described above. In one exemplary embodiment, suitable inorganic
oxides will be obtained by the calcination of inorganic oxides
which lack the requisite surface acidity but which are otherwise as
described above and which are commercially available.
[0059] In one embodiment, suitable inorganic oxides will be
obtained by heating a commercially available and otherwise suitable
inorganic oxide to a temperature of at least 550.degree. C. In
another embodiment, suitable inorganic oxides will be obtained by
heating an otherwise suitable and commercially available inorganic
oxide to a temperature of from 300 to 500.degree. C. In one
exemplary embodiment, suitable inorganic oxides will be obtained by
heating an otherwise suitable and commercially available inorganic
oxide to a temperature of from 400 to 450.degree. C. under a flow
of nitrogen. After preparation, the sorbent may be stored under dry
nitrogen until use.
[0060] It will be appreciated that the disclosed absorbents may in
one embodiment comprise metals and metal oxides such as Group VIIIA
metals, Group IVA, Group IVB and the like.
[0061] However, in one embodiment, the disclosed adsorbents may
optionally be untreated with any metals or metal oxides other than
those discussed above in the context of inorganic oxides. That is,
in one embodiment, the disclosed adsorbents will consist
essentially of the inorganic oxide having a surface acidity
characterized by a pK.sub.a of at least -3. In another exemplary
embodiment, the disclosed adsorbents will consist essentially of an
inorganic oxide having a surface acidity characterized by a
pK.sub.a of at least -3 and that is substantially free of the
metals and metal oxides traditionally employed as desulfurization
catalysts or absorbents. In another exemplary embodiment, the
disclosed adsorbents will consist essentially of an inorganic oxide
having a surface acidity characterized by a pK.sub.a of at least -3
and that is substantially free of the metals and metal oxides such
as Group VIIIA metals, Group IVA, Group IVB and the like.
[0062] Referring now to FIGS. 1 and 2, a non-limiting example of a
fuel filter 10 constructed in accordance with an exemplary
embodiment is illustrated. In accordance with an exemplary
embodiment, the fuel filter is a diesel fuel filter. Here fuel
filter 10 comprises a housing 12 configured to have at least one
inlet opening 14 and at least one outlet opening 16 to define a
flow path 18 therethrough.
[0063] In accordance with one exemplary embodiment (FIG. 1) the
fuel filter will comprise filter media 20 which is configured to
filter fuel. In accordance with an exemplary embodiment of the
present invention the filter media comprises an adsorbent
configured to remove sulfur from the fluid passing through the
filter.
[0064] Filter 10 also comprises an additive cartridge 22, which
contains a lubricant additive or lubricity additive 24 to be
dispersed into the fuel. Thus, cartridge 22 provides a means for
adding the lubricity agent back into the fuel.
[0065] In addition to media 20 and in an alternative exemplary
embodiment (FIG. 2) an adsorbent material 26 is positioned in the
flow path 18 to also filter the fuel, namely remove sulfur from the
fuel. Non-limiting examples of adsorbent material 26 are found in
U.S. patent application Ser. No. 11/674,913, filed Feb. 14, 2007,
the contents of which are incorporated herein by reference
thereto.
[0066] In the embodiment illustrated in FIG. 2, the additive
cartridge 22 is positioned in the flow path to disperse the
lubricity additive into the fuel after the fuel has been filtered
by adsorbent material 26 so that the lubricant or lubricity
additive is not scrubbed from the fuel. In accordance with
exemplary embodiments of the present invention and regardless of
the location of the additive cartridge (e.g., before are after the
adsorbent material) the additive cartridge can have the same
configuration as those illustrated in the following U.S.
Provisional Patent Applications Ser. No. 60/889,728 filed Feb. 13,
2007 and Ser. No. 60/910,772 filed Apr. 9, 2007, the contents each
of which are incorporated herein by reference thereto. Another
non-limiting configuration of the additive cartridge is also
illustrated in U.S. patent application Ser. No. 11/846,265 filed
Aug. 28, 2007, the contents of which are also incorporated herein
by reference thereto.
[0067] In one exemplary embodiment, the additive cartridge is
located within the fuel filter or alternatively, the additive
cartridge is in fluid communication with a fluid flow path of a
fuel circuit (e.g., a system comprising a separate fuel filter and
a separate additive cartridge each in fluid communication with a
fuel stream), wherein the lubricity additive is slowly metered out
into the fuel stream or it is pumped out or released by a value
into the fuel stream when a signal is received from a sensor
configured to detect levels of the lubricating additives in the
fuel. Another non-limiting filter configuration is illustrated in
FIG. 3.
[0068] In accordance with an exemplary embodiment, additive
cartridge 22 may comprise a plurality of openings in order to
disperse the additive, which may be in any form (e.g., liquid, gel,
solid, pellets, etc.). Alternatively and referring now to FIG. 4,
additive cartridge 22 may also comprise a metering pump and/or
acuatable valve 30 for metering of the additive. In this
embodiment, the fuel filter may be a component of a system 40
having a plurality of sensors or a single sensor 50 monitoring the
lubricant additive content in the fuel. Accordingly and when a
predetermined level is detected the pump or valve is
activated/opened to disperse the additive. The predetermined level
corresponds to a state of the sensed fuel wherein the lubricating
additives are below a desired level.
[0069] Alternatively, and as illustrated by the dashed lines in
FIG. 4, the additive cartridge may be a separate component in fluid
communication with fluid flow through the system wherein the
lubricating additive is slowly released into the fuel or is pumped
into the fuel or an actuatable valve is opened to release the
additive into the fuel. In this embodiment, the additive cartridge
is separately removable from the fuel circuit in order to allow for
replenishment of the additive in the additive cartridge.
[0070] In one exemplary embodiment, the additive cartridge is
located in the fuel filter and the same is removed and replaced
with the fuel filter. As discussed above, the fuel filter may
further comprise a pump or actuatable valve that receives commands
or signals from a controller to release the additive into the fuel
passing through the filter. In yet another alternative the additive
cartridge is located within the fuel filter and the same is
configured to slowly meter out the additive into the fuel. In this
embodiment, the additive cartridge may be upstream or downstream
from the adsorbent of the filter media.
[0071] In one exemplary embodiment, the apparatus, method or means
for monitoring and controlling the release of lubricating additive
is an on-board control apparatus comprising a plurality of sensors
50 each providing signals to a microprocessor or controller 70
comprising programmable logic that is configured to receive signals
from the plurality of sensors and provide signals to the fuel
filter in order to release the additives in the fuel stream wherein
the same can be received into the fuel stream without being
filtered out by the sulfur removing filter.
[0072] It is understood that a controller operating in response to
a computer program may implement the processing of the above
description. In order to perform the prescribed functions and
desired processing, as well as the computations therefore, the
controller may include, but not be limited to, a processor(s),
computer(s), memory, storage, register(s), timing, interrupt(s),
communication interfaces, and input/output signal interfaces, as
well as combinations comprising at least one of the foregoing.
[0073] As described above, algorithms for implementing exemplary
embodiments of the present invention can be embodied in the form of
computer-implemented processes and apparatuses for practicing those
processes. The algorithms can also be embodied in the form of
computer program code containing instructions embodied in tangible
media, such as floppy diskettes, CD-ROMs, hard drives, or any other
computer-readable storage medium, wherein, when the computer
program code is loaded into and executed by a computer and/or
controller, the computer becomes an apparatus for practicing the
invention. Existing systems having reprogrammable storage (e.g.,
flash memory) that can be updated to implement various aspects of
command code, the algorithms can also be embodied in the form of
computer program code, for example, whether stored in a storage
medium, loaded into and/or executed by a computer, or transmitted
over some transmission medium, such as over electrical wiring or
cabling, through fiber optics, or via electromagnetic radiation,
wherein, when the computer program code is loaded into and executed
by a computer. When implemented on a general-purpose
microprocessor, the computer program code segments configure the
microprocessor to create specific logic circuits.
[0074] These instructions may reside, for example, in RAM of the
computer or controller. Alternatively, the instructions may be
contained on a data storage device with a computer readable medium,
such as a computer diskette. Or, the instructions may be stored on
a magnetic tape, conventional hard disk drive, electronic read-only
memory, optical storage device, or other appropriate data storage
device. In an illustrative embodiment of the invention, the
computer-executable instructions may be lines of compiled C++
compatible code.
[0075] In an exemplary embodiment the controller includes logic for
evaluating signals from the plurality of sensors to determine if
the lubricating additive in the fuel filter is to be released into
the fuel stream. In one non-limiting embodiment, a means for
controlling the release of the sulfur will comprise a circuit and
sensor for identifying a predetermined level of lubricating
additive.
[0076] Referring now to FIGS. 5-8, there is shown a fuel filter 10
according to a non-limiting exemplary embodiment of the invention.
The fuel filter generally includes a hollow cylindrical housing 12
which defines a hollow chamber therein, wherein media 20 is
disposed in the chamber, and an additive cartridge or dispersement
device 22 is also retained inside the housing chamber.
[0077] In one embodiment, the housing also includes a base plate 80
sealingly attached to the case or housing. A foraminous center tube
may, optionally, be provided within the filter housing to
supportively reinforce media 20 thereon.
[0078] The housing base plate includes a plurality of inlet ports
comprising inlet path 14 and the base plate also includes a central
outlet port defining outlet path 16. In one non-limiting
embodiment, the outlet port has a plurality of female threads
formed therein, to allow rotatable mounting of the filter on an
externally threaded hollow tubular fitting (not shown). If
necessary, an annular external seal or gasket 82 fits engagingly
into a groove formed at the bottom surface of the base plate, to
resist leakage outwardly from the base of the filter.
[0079] In addition and in one embodiment, a gasket 86 is disposed
between the additive cartridge or basket 24 and the filter media
20.
[0080] In one non-limiting exemplary embodiment, the additive
cartridge includes a housing portion 88 having a first chamber 90
and a second chamber 92. First chamber 90 is separated from second
chamber 92 by a pair of dividing walls 94 and 96. In one embodiment
a liquid additive is disposed in chambers 90 and 92. A metering
opening 98 is provided to allow the additive of first chamber 90 to
pass therethough during usage of the filter. In accordance with an
exemplary embodiment metering opening configured to meter out the
additive. Thus, the additive is slowly metered out over the useful
life of the filter. Furthermore, a single opening may be provided
or multiple openings may be provided for fluid communication to
chamber 90.
[0081] Similarly a metering opening 100 is provided to allow the
additive of second chamber 92 to pass therethough during usage of
the filter. In accordance with an exemplary embodiment metering
opening configured to meter out the additive. Thus, the additive is
slowly metered out over the useful life of the filter. Furthermore,
a single opening may be provided or multiple openings may be
provided for fluid communication to chamber 92.
[0082] In accordance with one exemplary embodiment, chamber 90
comprises one lubricity additive and chamber 92 comprises another
lubricity additive or another fuel additive, each being distinct
from one another.
[0083] Of course, other configurations are contemplated in
accordance with exemplary embodiments of the present invention. For
example, the housing may be configured to have multiple chambers
and multiple metering holes. Alternatively, the housing may be
configured to have only a single chamber and a single metering hole
or plurality of metering holes thus only one additive is provided
by the single chamber of the additive cartridge or dispersement
device.
[0084] In accordance with an exemplary embodiment of the present
invention the additive or additives are any one of liquids, gels,
pellets, combinations thereof or equivalents thereof. In one
exemplary embodiment, the metering openings are sealed with a fuel
soluble material such that the same become dislodged from the
metering openings during use of the fuel filter. Moreover, sealing
of the openings allows the additives to be placed in the cartridge
during assembly and filling of the cartridge.
[0085] As illustrated in FIGS. 7A-7C, the second chamber 92 is
larger than the first chamber 90 thus, structural ribs 102, if
necessary, are located in the second chamber. Alternatively, second
chamber 92 is constructed without structural ribs 102. Accordingly,
a larger amount of additive can be placed in the second chamber as
opposed to the first chamber. The structural ribs are angled such
that they will not interfere with the fluid flow of the additive
from the chamber. In other words, the structural ribs at one point
will terminate at a bottom surface of the housing (e.g., opposite
cap 112), which is proximate to the metering opening(s).
Furthermore and as applications require the size of the chambers or
chamber may vary as the required amounts of the additives
varies.
[0086] In addition, the housing has neck portions on either side of
the housing for engagement with the outlet opening of the base
plate and the center opening of the filter media. This will allow
for ease of placement as well as providing a fluid seal for fluid
transfer through the dispersement housing.
[0087] In accordance with an exemplary embodiment of the present
invention, the housing will have a neck portion 122 that depends
away from the housing such that when the same is fluidly sealed to
the outlet opening of the base plate 80 a gap is maintained between
a surface of the additive cartridge and the inlet openings of the
base plate in order allow fluid flow over the top of the additive
cartridge and then along the side walls of the cartridge containing
the metering opening or openings and then through the filter media
and then ultimately out the outlet opening of the filter. In one
embodiment, an outlet path 120 is positioned in the additive
cartridge and is in fluid communication with the outlet path of the
filter. Accordingly, and as fluid flows the metering opening or
opening additive stored in the dispersement device is released into
fluid or fuel flowing past the additive cartridge or dispersement
device.
[0088] It being understood that the outer periphery of the additive
cartridge and the filter media are slightly smaller than the inner
dimension of the housing of the filter such that fluid flowing into
the inlet openings passes through a gap between the top of the
additive cartridge and the base plate and then into a gap or flow
path defined by the outer periphery of the housing of the additive
cartridge and the outer periphery of the filter media and the inner
dimension of the housing of the filter, wherein the fluid then
flows into the filter media and back out of the filter housing via
the outlet path defined by openings in the filter housing and if
applicable the filter media and the additive cartridge. In one
non-limiting exemplary embodiment, the outer periphery of the
filter media and the housing of the additive cartridge are
substantially the same thus making insertion of the filter media
and the dispersement device or additive cartridge into the housing
simple. Furthermore, there is no requirement to resize the filter
housing to accommodate the additive cartridge. For example, an
existing filter housing design without an additive cartridge may be
used by simply reducing the length of the filter media to
accommodate for the height of the additive cartridge.
[0089] FIGS. 8A-8C illustrates a cap 110 that is configured to be
secured to housing 88 after the additive or additives are disposed
therein. In accordance with an exemplary embodiment of the present
invention the cap is circular or disk shape with an opening 112
configured to receive a neck portion 114 of the housing therein. Of
course, other configurations are contemplated to be within the
scope of exemplary embodiments of the present invention. As
illustrated, the neck portion 114 will extend past cap 110 to
provide a feature for receipt into an opening of an end cap or end
of the filter media. Cap 110 in one exemplary embodiment will have
an annular feature 116 for receipt in an annular groove 188 of the
housing. In one embodiment feature 116 will provide a heat staking
member for securement of the cap to the housing by a vibration
welding method, ultrasonic welding method or spin welding.
Alternatively or in addition to the aforementioned welding
techniques an adhesive is used to secure the feature into the
groove. Similar features and methods may be employed to secure a
peripheral end of the cap to the outer walls of the housing.
Alternatively, the cap can be positioned such that the feature 116
is disposed on an exterior of the cartridge housing and the feature
is used to align and seal the additive cartridge with the end cap
or outlet opening of the filter housing.
[0090] In accordance with an exemplary embodiment a method of
supplying an additive in an fuel filter is provided, the method
comprising: forming a dispersement device housing with at least one
chamber, sealing the at least one metering opening with a fuel
soluble material the metering opening being in fluid communication
with at least one chamber when the fuel soluble material is removed
from the metering opening; sealing the dispersement device housing
with a cap, the cap being configured to seal the at least one
chamber within the dispersement device housing; and locating the
dispersement device housing within a filter, the filter having a
flow path such that fluid flowing into and out of the filter must
be in fluid communication with additives being dispersed from the
metering opening in the additive chamber.
[0091] Accordingly, the housing is first filled with an additive
and then the housing is sealed with a cap. Since the cartridge in
one embodiment is disposed between the filter media and the base
plate or after the filter media and an outlet opening the housing
may be inverted so that cap is disposed between the end or end cap
of the media and the housing of the additive cartridge.
Alternatively and depending on the configuration of the filter the
cartridge may not need to be inverted during its installation.
[0092] Referring now to FIG. 9 other configurations of the fuel
filter are illustrated. Here fluid flows into the filter on one
side and exits another side of the filer wherein the adsorbent or
filter media 20 is disposed in the fluid path through the filter.
In one embodiment, the additive cartridge is disposed between the
inlet opening and the filter media (e.g., upstream from the filter
media) or alternatively the additive cartridge is disposed between
the outlet opening and the filter media (e.g., downstream, from the
filter media). In yet another alternative, a pair of additive
cartridges are employed one between the inlet opening and the
filter media and the other between the outlet opening and the
filter media.
[0093] It will be appreciated throughout this discussion that the
singular forms "a", "an" and "the" include plural referents unless
the context clearly dictates otherwise. Similarly, throughout
"optional" or "optionally" means that the subsequently described
event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not. Likewise, the modifier "about" used in
connection with a quantity is inclusive of the stated value and has
the meaning dictated by the context (e.g., includes the degree of
error associated with measurement of the particular quantity).
[0094] While the invention has been described with reference to one
or more exemplary embodiments, it will be understood by those
skilled in the art that various changes may be made and equivalents
may be substituted for elements thereof without departing from the
scope of the invention. In addition, many modifications may be made
to adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *